India is the largest producer of pulses around 14.5 million tones annually. Pulses commonly known as dal in India are an important component of both the vegetarian as well as the nonvegetarian diet in India. Among the North Eastern States, Assam is the largest producer of pulses.

1. FOOD PROCESSINGFOOD PROCESSING
Profitable Food ProcessingProfitable Food Processing
Business Idea ( Dal Milling )Business Idea ( Dal Milling )
Shelke G.N
Assistant Professor
Department of Food Engineering
CFT Ashti,
Maharashtra 414202
Phone: +919561777282, +918605957182
E-mail: shelkeganesh838@gmail.com

2. Processes which depend primarily on physical forces to accomplish the
desired separation of components
Introduction
Food processing
Food processing is the transformation of
raw ingredients, by physical or chemical
means into food, or of food into other
forms.
Food processing combines raw food
ingredients to produce marketable
food products that can be easily
prepared and served by the consumer.

3. Processes which depend primarily forces to accomplish the
desired separation of components
Advantages of Processed Foods
We get food materials out of season.
It prevents spoilage of food stuff.
It enables the availability of food
material at distant places.
Storage period increases

4. Processes which depend primarily forces to accomplish the
desired separation of components
INTRODUCTION
India is the largest producer of pulses
around 14.5 million tones annually.
Pulses commonly known as dal in India are
an important component of both the
vegetarian as well as the nonvegetarian
diet in India.
Among the North Eastern States, Assam
is the largest producer of pulses.

5. Processes which depend primarily forces to accomplish the
desired separation of components
INTRODUCTION
It is estimated that more than 75% of
the pulse produced is converted into dhal.
Dhal milling is probably the third largest
of food processing industry after rice
and wheat.
Milling of pulse is practiced as a small-scale
rural operation from ancient times and more
recently as a large commercial operation.

6. Processes which depend primarily forces to accomplish the
desired separation of components
Pulses are the main sources of protein
in the Indian diet.
There are different varieties of pulses
namely Chana, Mung, Masur, Urad
and Tur dal.
The conversion of pulse grains into
dal through the process of milling.
Wherein dal is split into smaller sizes
rendering it convenient for cooking.
It is one of the important food
processing industry usually in the
medium and small scale sector

7. Processes which depend primarily forces to accomplish the
desired separation of components
WHY SMALL SCALE ?
Large scale dhal milling industries need
Huge capital investment.
 While small scale or tiny scale units produce
inferior quality product with lesser yield
compared to large scale dhal mills.
 Although some small-scale units
(e.g., mini dhal mill) give satisfactory
performance.

8. Processes which depend primarily forces to accomplish the
desired separation of components
MARKET POTENTIAL
The all India per capita consumption
of pulses is about 2.8 kg per year.
Considering national average of
2.8 kg / year and population of
110.0 Crore, the estimated demand
for pulses / split pulses is approx. 30.8 Lac
MT per annum.
At conservative estimate also, there is
demand of approx.25.0 Lac MT/p.a, out
of which almost 60% is met from domestic
crop and 40 % is met through import of
pulses from various countries.

9. Processes which project report in hand. Basically, it helps in arranging finance,
preparing the unit, purchasing and installing the right machinery and in another
operational aspect. It is better to establish the unit in industrial are where you can
arrange worker and transport facility. Before installing the machinery, having a layout
plan and implementation schedule is essential.
forces to accomplish the
desired separation of components

10. Processes which depend primarily forces to accomplish the
desired separation of components
Manufacturing Process
The stones and foreign matter are removed
and the pulse is graded in 2-3 different size.
It is soaked in water for 60-90 minutes and heaped
for uniform moisture absorption and dried in the
sun for 2-3 days till fully dried.
It is fed into mini dal mill at 90-100 rpm.
The split dal falls in the cone chamber from
control plate, which is separated into whole
dal, broken and husk through an aspirator.

11. Processes which depend primarily forces to accomplish the
desired separation of components
Conti…..
Manufacturing Process
The fractions are packed separately.
The Mini dal mill can mill Bengal gram,
Bokla, Kesari, Pea, Soybeans pigeon pea
in a single operation at 100-130 kg per hour.
Lentil (masoor) is milled in 2 operations
with output of 100-125 kg/hour.
Black gram, green gram and moth beans
are milled with double operation with
output of 60-80 kg dal/hour.

12. Processes which depend primarily forces to accomplish the
desired separation of components
The important steps
 Cleaning
Milling
De-husking and cleaning and
 Applying Oil in some Dal
 Weighing and Packing

13. Processes which depend primarily forces to accomplish the
desired separation of components

14. Processes which depend primarily forces to accomplish the
desired separation of componentss

15. Processes which depend primarily forces to accomplish the
desired separation of components

16. Processes which depend primarily forces to accomplish the
desired separation of componentss
License Required
In starting a business, you will
need to register the business
first with ROC (Register of Companies).
You have to apply for a Food Business
Operating License from fssai
You will need to ensure the compliance
of all the fire safety guidelines.
You may also register your unit
as SSI from local DIC office.
You also need to have clearance from
Pollution Control Board.

17. Processes which depend primarily forces to accomplish the
desired separation of components
Business Finance
In initiating a business, you will
need to arrange two types of capital.
One is fixed capital for setting up the
unit and purchasing machinery.
The second one is working capital.
Hire purchase leasing is available
from banks for machinery purchase.
You can avail a cash credit or overdraft
account to serve the requirement
of working capital.

18. Processes which project report in hand. Basically, it helps in arranging finance,
preparing the unit, purchasing and installing the right machinery and in another
operational aspect. It is better to establish the unit in industrial are where you can
arrange worker and transport facility. Before installing the machinery, having a layout
plan and implementation schedule is essential.
forces to accomplish the
desired separation of components
Business Unit Establishment
It is always recommended to have
customized project report in hand.
Basically, it helps in arranging finance,
preparing the unit, purchasing and
Installing the right machinery and in
another operational aspect.
It is better to establish the unit in industrial
are where you can arrange worker and
transport facility.
Before installing the machinery, having a
layout plan and implementation schedule
is essential.

19. Processes which depend primarily forces to accomplish the
desired separation of components
Business Machinery
According to the desired product and
production output, you can establish unit
With following machinery.
Grader,
Dal Mill,
Sheller,
Polisher,
Buff Polisher,
Roller
Varam Machine,
Screens,
Dryer etc.

20. CAPACITY :- 500 MT per annum

21. CAPACITY :- 500 MT per annum
PROJECT ECONOMICS
TOTAL CAPITAL REQUIREMENTS
Fixed Capital (Rs. in lakh)
Land Own
Site Development 0.45
Building (working shed 750 Sq.ft. 4.87
Raw material godown, finished product
Godown, Office room)
Plant and Machinery 1.84
Misc. Fixed Assets 0.50
Preliminary/Pre-operative expenses 0.30
Total : 7.96

22. CAPACITY :- 500 MT per annum
Working Capital Requirement
Amount
(Rs.in lakh)
Raw material and
Consumables 1 month 9.23
Finished goods 1 week 2.87
Working expenses 1 month 0.42
Receivables 1 week 2.93
Total : 15.45

23. CAPACITY :- 500 MT per annum

24. CAPACITY :- 500 MT per annum
COST OF PRODUCTION
(Rs. in lakh)
Raw material and consumables 110.75
Utilities 3.34
Wages and Salaries 1.38
Plant Overheads and repairing & maintenance 0.35
Depreciation 0.70
Administrative Expenses 0.36
Interest 2.46
Selling expenses @ 5% of annual sales 6.75
126.09 lakhs
Operating profit Rs. 8.91 lakhs
Return on Sales 66%

25. CAPACITY :- 500 MT per annum
The cost of raw material and consumables are as follows:
1. Dal (various quality) @ of Rs. 25,000/- Rs. 110.00 lakhs
2. Packing material (Lumpsum) Rs. 0.75 lakh
Total: Rs. 110.75 lakhs
COST OF UTILITIES AND OVERHEAD
The power requirement for the milling plant:
1. For running the automatic dal mill with 25 HP Motor 18.65 kw
2. For internal lighting + general load : 6 Kw
Total : 24.65 KW
The total daily requirement of power
(26 Kw × 16 hrs ×2 shifts) × 8) = 320 Kwh
The daily power bill (320 Kwh × Rs. 4) = Rs. 1280/-
Total cost of power per annum (i.e. 300 working days) = Rs. 3.84 lakhs

26. CAPACITY :- 500 MT per annum

27. CAPACITY :- 500 MT per annum

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